Metal strip roll forming stand

ABSTRACT

A roll forming stand including a plurality of pairs of forming rolls for progressively shaping a light gauge metal strip, such as an aluminum metal strip to a desired shape and wherein one roll of each of the pairs of rolls is resiliently positioned for movement away from its companion roll whereby if an obstruction in rolling is met, the rolls can move apart and wherein a unitary drive system is provided for the plurality of pairs of forming rolls.

I United States Patent 11 1 1111 3,785,191 Dewey 1 Jan. 15, 1974 METAL STRIP ROLL FORMING STAND Primary Examiner-Milton S. Mehr [76] lnventor. Herbert F. Dewey, 1368 Mac Dr.,

,. Stow, Ohi 44224 Attorney- (Tlham 8c (jldham L.P.A.

[22] Filed: May 26, 1972 [57] ABSTRACT [21] Appl. No.: 257,308

A roll formmg stand 1nclud1ng a plurality of pairs of forming rolls for progressively shaping a light gauge [52] US. Cl. 72/181 metal strip, h as an aluminum meta] strip to a [51] Int. Cl BZld 5/08 sired shape and wherein one roll of each of the pairs [58] Fleld of Search 72/181, 182, 179, of rolls is resiliently positioned for movement away 72/178 from its companion roll whereby if an obstruction in rolling is met, the rolls can move apart and wherein a [56] References C'ted unitary drive system is provided for the plurality of UNITED STATES PATENTS pairs of forming rolls. l,3l7,58l 9/1919 Kipniss et al. 72/178 2,47 ,490 5 1949 Mercer 72/178 3 Clam, 5 D'awmg Flgures PAIENTEDJAN151974 3.785.191

FIG. 3 FIG. 4

a: I F 9 METAL STRIP ROLL FORMING STAND This invention relates to roll forming stands, and especially to an uncomplicated roll forming stand and unitary drive means for shaping light gauge metals, such as aluminum strip.

BACKGROUND OF INVENTION Heretofore there have been many different types of metal roll forming stands provided wherein a continuous strip of metal will be shaped progressively to a predetermined contour as it passes through the series of forming rolls. These forming rolls and apparatus have normally been massive, and very strong and heavy.

There has been some widespread use of metal siding on homes at the present time as a protective cover thereon, and it has been difficult, if not impossible in most instances, to provide any decorative metal shapes around windows, doors and other openings in the build ing. The present invention is on apparatus for shaping light gauge metal, such as aluminum strip, one use for the end product being to cover window frames or other frame means in the building to provide a decorative, but durable covering material for trim on the outside of the building structure. The metal shaping can be preformed at a central location and be readily transported to the job for cutting, sizing and installation.

In forming or shaping light gauge metal, it is desirable that the rolls be durable and be adapted to overcome and automatically compensate for any irregularities in the strip being processed and to accept a thicker gauge of material than that gauge for which the rolls were originally set so that the roll forming stand will be durable and have a long operating life with a minimum of maintenance.

The general object of the present invention is to provide a new and improved roll forming stand or apparatus especially adapted for shaping a light gauge metal strip to a predetermined contour by a series of progressivelycontoured pairs of forming rolls. 1

Another object of the invention is to provide a roll forming stand or apparatus which is characterized by its durability and by its automatic adjustment or compensation for irregularities in the strip of metal being processed or in the processing of heavier gauge material than contemplated when setting up the apparatus. Other objects of the invention are to provide an improved, resilient mounting of at least one roll in each of a series of pairs of metal forming rolls; to provide a relatively lightweight, sturdy, self-contained metal shaping apparatus; and to provide a maintenance free low cost roll stand for light gauge metal shaping actions.

The foregoing and other objects and advantages of the invention will be made more apparent as the specification proceeds.

Reference now is directed to the accompanying drawings, wherein:

FIG. 1 is a side elevation of the metal roll stand and forming apparatus of the invention;

FIG. 2 is a plan view of the apparatus of FIG. 1;

FIG. 3 is an enlarged vertical section taken on lines 3-3 of FIG. 1;

FIG. 4 is a vertical section taken on line 4-4 1; and

FIG. 5 is a fragmentary vertical section taken on line 55 of FIG. 3.

ofFIG.

INVENTIVE SUBJECT MATTER A roll forming apparatus including a frame means on which a plurality of pairs of forming rolls are operatively journalled for progressively shaping a metal strip passed therethrough to a predetermined contour are mounted, means retain the rolls of the pairs of rolls in predetermined spaced relationship, and means resiliently retain one of the rolls of each pair of rolls in such operative spaced relationship to its companion roll, but where one roll of each pair is free for movement under stress to a position spaced further from the one stationary roll of each set of rolls.

Reference now is made to the details of the structure shown in the drawings, and a roll forming apparatus or stand is indicated as a whole by the numeral 10. This apparatus 10 includes a suitable elongated frame 12 which is of relatively open construction and includes, for example, pairs of end supports or legs 14 and upper and lower support bars or members 16 and 18, respectively, that are secured to the legs 14 and form a unitary structure therewith.

The roll forming apparatus of the invention is adapted to form, progressively, a continuous strip of metal, such as a strip 20 supplied thereto to a desired contour by a progressive rolling or forming action. Thus, a plurality of pairs of complementary shaped forming rolls 22, 24, 26, 28, 30 and 32 are provided in this particular embodiment of the invention and wherein each of these rolls, such as the roll 22 and its companion lower roll 22a as shown in FIG. 3 have the metal strip 20 pass therethrough. The strip is progressively shaped to a desired end contour as shown in FIG. 4 where the strip has been pulled between the roll 32 and its lower roll 32a.

FIG. 4 of the drawings shows that each of the forming rolls, such as the rolls 22 or 22a, for example, has a mounting shaft 34 or 34a extending from each end thereof and with these shafts being journalled in suitable members, such as bearings 36 and 36a that in turn are mounted in carrier blocks or members 38. These shafts 34 usually are integral with the individual rolls which they support. The shaft 34a is specifically received in the bearing 36a which in turn is mounted on a corresponding block 38a. FIG. 3 shows that the lower support bar or member 18 has the positioning block 380 engaged therewith and supported thereon whereas a spacer member or tube 40 is positioned between the adjacent faces or surfaces of the blocks 28 and 38a. The assembly of the pairs of rolls is. completed by elongated bolts or equivalent members 42 that extend between the upper and lower support bars 16 and 18 in the frame, the bearing blocks 38 and 38a, and spacers 40. The blocks 38 and 38a are slidable on the bolts 42.

In order to provide an effective operative positioning for the bearing blocks 38 in the system, a relatively sturdy coil spring 44 is positioned around each of these bolts to urge the blocks 38 down towards the blocks 38a at all times and maintain the desired predetermined spaced relationship between the individual rolls of the pairs of the forming rolls. However, when excessive forces are applied to the pair of forming rolls or when a thickened strip of metal is attempted to be forced or moved through a pair of rolls, then the upper roll of each roll stand or pair will automatically adjust its position and move radially away from the companion roll whereby the forming rolls would not be damaged. The roll spacing is determined by the spacers 40. The upper roll of each pair of rolls is the female roll of such pair and readily moves vertically under abnormally high stress conditions.

The drawings shown that one end of the shaft 34 can extend axially beyond the frame 12 and have a drive member, such as a sprocket 46, secured thereto. One of these sprockets 46 is secured to a positioning shaft for each of the rolls in the apparatus, usually, and a drive chain 48 is operatively engaged with and extends around these individual sprockets 46. Drive means for the apparatus is provided, as by a suitable motor 50 that has a drive sprocket 52 thereon and the chain 48 extends around such sprocket to drive the rolls of the roll stand for metal strip forming action. The complete roll stand can be moved from place to place, if desired, for use and it is of low cost, maintenance free, durable construction. Guide sprockets 54 and 56 aid in forming the operative loop of the chain 48. Any desired type of a take-up arm 58 and a sprocket means thereon can engage with the chain 48 to maintain desired tension therein. Resilient means may be associated with the arm to aid in maintaining operative tension on the chain 48. The chain 48 may drive only one roll of each pair of rolls, if desired.

From the foregoing, it is believed that a new and improved metal forming apparatus has been provided and that the objects of the invention have been achieved.

While one complete embodiment of the invention has been disclosed herein, it will be appreciated that modification of this particular embodiment of the invention may be resorted to without departing from the scope of the invention.

What is claimed is:

1. A roll forming apparatus including a frame means, a plurality of pairs of forming rolls journalled on said frame means, said forming rolls progressively shaping a metal strip passed therethrough to a predetermined contour, means positioning the rolls of said pairs of rolls in predetermined spaced relation, means resiliently retaining said rolls in operative, spaced relation; and

an upper roll and a lower roll being provided in each of the pairs of rolls, said resilient retaining means include vertically extending bolt means engaging and extending between spaced portions of said frame means, upper and lower bearing carrier blocks for said rolls slidably and operatively engaging spaced portions of said bolt means, the carrier blocks for the lower roll of each pair of rolls being abutted on a portion of said frame, spacer means slidably engaging said bolt means intermediate the upper and lower bearing carrier blocks thereon to retain the rolls of the pairs of rolls in spaced relation, and coil springs on said bolt means compressively engaging said upper carrier blocks and said frame to urge said upper carrier block towards its associated lower block to space the rolls, normally, in a pair of rolls a predetermined distance.

2. A roll forming apparatus as in claim 1 where said rolls have shafts extending therefrom, a drive sprocket is mounted on the shaft of each roll, an endless chain operatively extends around said drive sprockets for each shaft of the pairs of rolls to drive all of said rolls from one course of movement of said chain, and means to drive said chain, the chain having a return course extending from a downstream end of the apparatus to an upstream end thereof.

3. A roll forming apparatus as in claim 1 where said upper roll of each of said pairs of rolls is the female roll and is adapted to move vertically away from its associated male roll under abnormally high stress but to maintain a fixed spaced relation with its associated male roll for normal rolling pressures. 

1. A roll forming apparatus including a frame means, a plurality of pairs of forming rolls journalled on said frame means, said forming rolls progressively shaping a metal strip passed therethrough to a predetermined contour, means positioning the rolls of said pairs of rolls in predetermined spaced relation, means resiliently retaining said rolls in operative, spaced relation; and an upper roll and a lower roll being provided in each of the pair of rolls, said resilient retaining means include vertically extending bolt means engaging and extending between spaced portions of said frame means, upper and lower bearing carrier blocks for said rolls slidably and operatively engaging spaced portions of said bolt means, the carrier blocks for the lower roll of each pair of rolls being abutted on a portion of said frame, spacer means slidably engaging said bolt means intermediate the upper and lower bearing carrier blocks thereon to retain the rolls of the pairs of rolls in spaced relation, and coil springs on said bolt means compressively engaging said upper carrier blocks and said frame to urge said upper carrier block towards its associated lower block to space the rolls, normally, in a pair of rolls a predetermined distance.
 2. A roll forming apparatus as in claim 1 where said rolls have shafts extending therefrom, a drive sprocket is mounted on the shaft of each roll, an endless chain operatively extends around said drive sprockets for each shaft of the pairs of rolls to drive all of said rolls from one course of movement of said chain, and means to drive said chain, the chain having a return course extending from a downstream end of the apparatus to an upstream end thereof.
 3. A roll forming apparatus as in claim 1 where said upper roll of each of said pairs of rolls is the female roll and is adapted to move vertically away from its associated male roll under abnormally high stress but to maintain a fixed spaced relation with its associated male roll for normal rolling pressures. 